Solenoid controlled variable pressure injector

ABSTRACT

A unit fuel injector adapted to receive fuel from a fuel supply at relatively low pressure and adapted to inject fuel at relatively high pressure into the combustion chamber of an internal combustion engine is provided, comprising an injector body having a first internal bore and an injector orifice and a plunger mounted for reciprocating movement within the first internal bore to define a variable volume fuel pressurization chamber including a cam actuated upper plunger portion and a lower plunger portion mounted in the first internal bore between the variable volume fuel pressurization chamber and the upper plunger portion. While the upper plunger portion is in its retracted position, low pressure fuel from the fuel supply is supplied to the variable volume fuel pressurization chamber. A spring is positioned within the first internal bore to bias the upper and lower plunger portions apart to thereby allow for variation of the volume of fuel which flows into the variable volume fuel pressurization chamber during each cycle of injection operation in dependence on the pressure of the fuel from the fuel supply. A valve assembly including a valve element mounted for reciprocating movement within a second internal bore controls the flow of fuel from the variable volume fuel pressurization chamber to the injector orifice. The valve assembly allows fuel to be discharged through the injector orifice only during the time when the upper plunger portion is in its fully advanced position so that injection pressure is independent of the velocity at which the upper plunger portion moves between its retracted and advanced position.

TECHNICAL FIELD

The present invention relates to an improved electronically controlledunit fuel injector for providing accurate control and variation of thetiming of injection, the metering of the proper quantity of fuel and thepressure at which the fuel is injected.

BACKGROUND OF THE INVENTION

Unit fuel injectors operated by cams, have long been used in compressionignition internal combustion engines for their accuracy and reliability.The unit injector typically includes an injector body having a nozzle atone end and a cam driven injector plunger mounted for reciprocatingmovement within the injector body. In the typical unit fuel injector, alink, which is cam actuated, physically communicates with a lower,intermediate or upper plunger which moves inwardly, during the injectionevent, to force fuel either into an injection chamber and out aninjector orifice or directly out of an injector orifice on acycle-by-cycle basis. To achieve optimal engine operation fuel must beinjected at very high pressure to cause the maximum possible atomizationof the injected fuel. In addition, the interval of injection needs to becarefully timed during each cycle of injector operation in dependenceupon the movement of the corresponding engine piston.

Internal combustion engines are subjected to a variety of external aswell as internal variable conditions ultimately affecting theperformance of the engine. Examples of such conditions are engine load,ambient air pressure and temperature, timing, power output and the typeand amount of fuel being consumed. In order to satisfy the increasedneed for higher engine efficiency and pollution abatement, accuratecontrol over and a means for varying (1) the timing of injection, (2)the metering of the proper quantity of fuel and (3) the injectionpressure in response to changing engine operating conditions isrequired.

Attempts to provide independent control over these parameters from onecycle to the next have, in most cases, been unsuccessful due, in part,to the way in which fuel is supplied to the injector. In most cases fuelis pumped from a source by way of a low pressure rotary pump or gearpump to the unit injector which may be thought of as a high pressurepump. Such high pressure pumps conventionally include a positivedisplacement piston driven by a cam which is mounted on an engine drivencam shaft. High pressure pumps of the electrical, mechanical, hydraulicor electromechanical types are known as well, however, these systemsoften lack reliable independent control over the various injectionparameters from cycle to cycle.

Other attempts to independently vary these key injection parametershave, in many cases, failed due to their dependence upon other engineoperating conditions. For example, injection pressure, in the typicalunit fuel injector, is dependent upon the velocity of the inwardmovement of a cam actuated injector plunger during the injection event.In unit fuel injectors of this type, the injector plunger ismechanically connected to the engine cam shaft and, as a result,injection pressure is dependent upon engine speed. Therefore, theinjection pressure cannot be adequately varied for each cycle ofinjection operation to provide improved efficiency in engine operationand pollution abatement.

A well known approach to solving the lack of cycle-by-cycle controlcapability is to employ a solenoid valve in combination with the unitinjector to vary the quantity and timing of injection during each cycle.For example, in U.S. Pat. Nos. 4,129,253 to Bader et al. and 4,392,612to Deckerd et al., an electromagnetic unit fuel injector is disclosedincluding a single, cam operated injector plunger, an electromagneticvalve for determining the beginning and ending of injection, and thus,the timing and quantity of fuel injected during each cycle of plungermovement, and a tip-mounted valve for resisting blow back of exhaustgases into the high pressure chamber of the injector while allowing fuelto be injected into the cylinder. Injector assemblies of this type areoften referred to as jerk-type unit injectors.

As is shown in the above-mentioned patents, injection pressure iscontrolled and determined by a fixed displacement pump structure so asto permit the intensification of the fuel pressure and injection of fuelto provide both a pilot and a main charge injection. Although the fuelpressure levels obtained during both high load and low load engineoperation is sufficient to provide for injection, the fixed displacementand volume of fuel supplied by the unit injector pump does not allow forhigh accuracy in the control of the timing of injection or metering of aquantity of fuel under varying conditions at or close to maximum peakpressures. The inability of these types of injectors to operate atmaximum peak pressures under varying conditions, from low load to highload engine operation, results in a degradation of the engines ultimateperformance.

Other unit fuel injection systems attempt to solve the lack ofcycle-by-cycle control capability by varying the quantity and timing ofinjection during each cycle by a collapsible hydraulic link toselectively change the effective length of the cam operated fuelinjector plunger. For example, in U.S. Pat. No. 4,463,901 to Perr etal., a unit fuel injector is disclosed including a three part, camoperated injector plunger defining within an internal bore a variablevolume injection chamber, a variable volume timing chamber and avariable volume compensation chamber in which is mounted a biasing meansfor biasing the plunger sections defining the compensation chamber inopposite directions to collapse the timing and injection chambers.Control and variation of the timing of injection for each cycle ofinjection operation is achieved in dependence upon the volume of fuelsupplied to the timing chamber, thereby defining the length of thehydraulic link formed therein. The amount of fuel is independentlycontrolled by the volume of fuel supplied to the injection chamber. Theamount of fuel supplied to the respective timing and injection chambersis affected by the spring constant of the biasing spring located in thecompensation chamber. While providing for accurate independent controland variation of the timing of injection and metering of the properquantity of fuel, the unit fuel injector of Perr et al. '901 does notallow for variation of injection pressure for each cycle of injectionoperation in response to the changing engine operating conditions,independent of engine speed. Similar types of unit fuel injectorsincluding two-part plunger assemblies are disclosed in U.S. Pat. No.4,531,672 to Smith, U.S. Pat. No. 4,281,792 to Sisson et al. and U.S.Pat. No. 4,235,374 to Walter et al.

In the typical unit fuel injectors, such as those discussed above, theactual cycle-by-cycle injection of the pressurized fuel through theinjector orifice is achieved by inward movement of a plunger connectedto a link driven by the engine cam shaft during the injection event.Injection pressure for each cycle of injection operation for injectorsoperating in this manner is dependent upon engine speed. Control overand variation of this parameter is necessary to achieve optimal engineoperation and is not possible where such control and variation isdependent on engine speed. In addition, to achieve and maintain themaximum peak pressure to ensure maximum possible atomization of theinjected fuel, the plunger, which travels inwardly during the injectionevent, must travel inwardly with an extremely high velocity and theinjection event must occur over a relatively short time span. Thetypical time interval for the injection event is in the range of 2-4milliseconds. High velocity movement of the plunger in a short timeperiod requires a high rate of acceleration, which, in a cam actuatedunit fuel injector, is determined by the cam profile.

As is well known, the contour or shape of the lift ramp of the cam Willdetermine the rate of acceleration of the plunger. To achieve thenecessary high velocity in a short period of time, a high rate ofacceleration is required which can only be achieved by a cam lobeexhibiting very sharp radii of curvature (i.e. sharply angled liftramp). The lift profile of the cam in a fuel injector that injects fuelin this manner is characterized by a lift ramp having a very sharp anglewhich is disadvantageous in that such a design greatly increases camhertz stresses, resulting in increased wear on the cam and cam followersurfaces.

Attempts have been made to provide a unit fuel injector in which theinjection event does not occur concurrently with the inward movement ofa plunger connected to the engine cam shaft (i.e., the cam, link andplunger assemblies), thereby, eliminating the need for the higher ratesof acceleration required by the fuel injectors described above. Forexample, U.S. Pat. No. 4,275,693 to Leckie discloses a fuel injectiontiming and control device wherein injection of fuel, which ispressurized by way of a plunger/piston arrangement, is carried out bythe use of a solenoid controlled sleeve tip valve, wherein the solenoidis mounted coaxially with the central axis of the injector body. Fuel issupplied to an accumulator, which is provided with a piston slidablydisposed in a bore, movable upwardly against the bias of a spring and arelief valve to relieve pressure within the accumulator above apredetermined level. The fuel is continuously maintained at a constantpressure level during the preinjection, injection and post-injectionevents. When the solenoid is activated, the tip valve allows a meteredportion of the pressurized fuel in the accumulator to be injectedthrough discharge passages. Pressurization of fuel within theaccumulator of the injector is disassociated from timing and duration offuel injection, which is controlled solely by the energization of asolenoid. Injection, thus, occurs independently of any mechanicalconnection to the cam shaft.

In the operation of the fuel injector disclosed in Leckie, the pressureof the fuel in the accumulator is relatively constant, resulting in acorresponding relatively constant injection pressure. Injection pressureis controlled by the spring constant of the spring biasing the pistondefining the accumulator in conjunction with the relief valvearrangement. Therefore, while independent of engine speed, the fuelinjector of Leckie cannot allow for variation of injection pressure foreach cycle of injection operation in response to engine operatingconditions to optimize engine efficiency and pollution abatement.Moreover, Leckie's use of a pressure relief valve causes the excessenergy stored in the fuel within the accumulator to be wastefully lostupon opening of the relief valve.

Consequently, there is a need for a unit fuel injector Wherein theinjection event does not necessarily occur concurrently with the inwardmovement of a plunger connected to the engine cam shaft, in which theaccurate control over and variation of the timing of injection, themetering of the proper quantity of fuel and the injection pressure ispossible independent of engine speed.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a unit fuel injectorwhich will allow for greater accuracy in the control and variation ofthe timing of injection, the metering of the proper quantity of fuel andthe injection pressure.

Another object of the present invention is to provide a unit fuelinjector wherein injection pressure can be varied for each cycle ofinjection operation substantially independent of engine speed.

A further object of the present invention is to provide a unit fuelinjector wherein fuel is injected through an injector orifice into acombustion chamber at a pressure level which is dependent on variationin the level of pressure of the fuel received from a fuel supply andwhich is independent of changes in the velocity of the reciprocatingmovement of a plunger mechanically connected to the engine cam shaft.

Yet another object of the present invention is to provide a unit fuelinjector wherein controlling the volume of low pressure fuel supplied toa variable volume fuel pressurization chamber during each cycle ofinjection operation allows for the accurate control and variation of thepressure at which fuel is injected through an injector orifice into thecombustion chamber of an engine within the same cycle of injectionoperation, thereby allowing for maximum average injection pressuresthroughout the full range of engine speeds.

Still another object of the present invention is to provide a unit fuelinjector wherein the energy stored in the fuel remaining in a variablevolume fuel pressurization chamber following each injection event isreturned to the engine cam shaft during each injection cycle due to theelastic compressibility of the fuel.

Yet another object of the present invention is to provide a unit fuelinjector wherein injection pressure may be varied in response to ahydraulic control signal and both the timing of injection and thequantity of fuel injected can be accurately controlled and varied duringeach cycle of injection operation in response to an electrical Controlsignal.

Still another object of the present invention is to provide a unitinjector wherein the inward movement of a plunger mechanically connectedto the engine cam shaft is decoupled from the injection event, therebysubstantially reducing hertz stresses placed on the mechanical portionsof the fuel injector resulting in less wear on the cam and cam followersurfaces.

Yet another object of the present invention is to provide an improvedcam operated unit fuel injector which includes a cam lobe devoid ofsharp radii of curvature, thereby providing a profile including aplunger advancement segment (i.e. lift profile) which is shaped to causethe injector plunger rate of acceleration and velocity to be relativelylow to reduce substantially the hertz stresses placed on the mechanicalportions of the fuel injector and to cause less wear on the cam and camfollower surfaces. In particular, it is an object of the disclosedinvention to achieve high injection pressure by means of a cam devoid ofthe sharp radii of curvature as would be required for achieving the samehigh level of injection pressure by means of conventional cam actuatedunit injectors.

Another object of the present invention is to provide an injector havinga plunger connected to a cam actuated link including a lower plungerportion and an upper plunger portion separated by a spring therebetweenwhich will allow the volume of fuel trapped in the injector to be variedresulting in a more compliant system able to achieve higher average fuelinjection pressures for each injection event given the same peakinjection pressure and the same amount of fuel discharged per cycle.

These and other objects of the present invention are achieved byproviding a unit fuel injector adapted to receive fuel from a fuelsupply at relatively low pressure and adapted to inject fuel atrelatively high pressure into the combustion chamber of an internalcombustion engine, comprising an injector body having a first internalbore and an injector orifice and a plunger mounted for reciprocatingmovement within the first internal bore to define a variable volume fuelpressurization chamber including a cam actuated upper plunger portionand a lower plunger portion mounted in the first internal bore betweenthe variable volume fuel pressurization chamber and the upper plungerportion. While the upper plunger portion is in its retracted position,low pressure fuel from the fuel supply is supplied to the variablevolume fuel pressurization chamber. A spring is positioned within thefirst internal bore to bias the upper and lower plunger portions apartto thereby allow for variation of the volume of fuel which flows intothe variable volume fuel pressurization chamber during each cycle ofinjection operation in dependence on the pressure of the fuel from thefuel supply. A valve assembly including a solenoid operated valveelement mounted for reciprocating movement within a second internal borecontrols the flow of fuel from the variable volume fuel pressurizationchamber to the injector orifice in dependence on an electrical controlsignal. The electrical control signal is timed to cause fuel to bedischarged through the injector orifice only during the time when theupper plunger portion is in its fully advanced position so thatinjection pressure is independent of the velocity at which the upperplunger portion moves between its retracted and advanced position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of the electronically controlled unitfuel injector designed in accordance with a preferred embodiment of theinvention.

FIG. 2A is a cross-sectional view of the solenoid controlled valveassembly wherein the valve is shown in its first position

FIG. 2B is a cross-sectional view of the solenoid controlled valveassembly wherein the valve is shown in its second position.

FIG. 3 is a schematic illustration of the sequential operation of theelectronically controlled unit fuel injector in accordance With thepresent invention.

FIG. 4 is a graph illustrating the resulting average pressure, link loadand link travel for the electronically controlled unit fuel injector ofFIG. 1 given a constant peak pressure and delivery of fuel per cycle.

FIG. 5 is a side view of a cam according to the present invention.

FIG. 6 is a graph illustrating generally the cam lift as a function ofcam rotation for the cam of FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Throughout this application, the words “inward”, “innermost”, “outward”and “outermost” will correspond to the directions, respectively, towardand away from the point at which fuel from an injector is actuallyinjected into the combustion chamber of an engine. The words “upper” and“lower” will refer to the portions of the injector assembly which are,respectively, farthest away and closest to the engine cylinder when theinjector is operatively mounted on the engine.

Referring to FIG. 1, fuel injector assembly 2 includes an injector body4 formed from an outer barrel 6, an inner barrel 8, a disc 9, a springhousing 10, and a nozzle housing 11. The inner barrel 8, disc 9, springhousing 10, and nozzle housing 11 are all held in abutting relationshipagainst the bottom of outer barrel 6 by means of an injector cup 12containing an internal cavity adapted to receive these elements instacked configuration as illustrated in FIG. 1. The outer end of theinjector cup 12 contains internal threads for engaging correspondingexternal threads on the lower end of outer barrel 6 to permit the entireunit injector 2 to be held together by simple relative rotation of cup12 with respect to the outer barrel 6. An outer housing 13 contains aninternal cavity adapted to receive injector cup 12. A coolant passage Cis also provided for directing the flow of coolant around the outerhousing 13 of the injector 2 to provide a means for cooling theinjector.

The outer barrel 6 contains first internal bore 15 for receiving atwo-part plunger assembly 24. The inner barrel 8 includes a secondinternal bore 14 adapted to receive a valve assembly 60 and a solenoidassembly 70. The spring housing 10 and nozzle housing 11 contain a thirdinternal bore 18 for receiving a tip valve assembly 19 including anaxially slidable pressure actuated tip valve element 20 and a spring 22which biases the tip valve element 20 into the closed position,illustrated in FIG. 1, and further includes injector orifices 17 formedat the innermost end of the nozzle housing 11. The injector orifices 17are positioned to communicate directly on one side with the combustionchamber of the engine (not shown) and on the other side to communicatewith the first internal bore 15 through a series of flow passages whichtogether form a transfer passage 16. As illustrated in FIG. 1, theinjector orifice 17 is normally closed by the tip valve element 20. Atip valve chamber 21 is defined by the tip valve element 20 and thethird internal bore 18. When the pressure of fuel within the tip valvechamber 21 exceeds a predetermined level, the tip valve element 20 movesupwardly (not shown) to allow fuel to pass through the injector orifices17 into the combustion chamber (not shown).

Positioned within the first internal bore 15 of the outer barrel 6 is aplunger assembly 24 including an upper plunger portion 26 connected to alink 32 adapted to reciprocate in response to a cam-actuated mechanism(not illustrated), and a lower plunger portion 28. Upper plunger portion26 is permanently biased towards its outermost position by a relativelyhigh pressure compression spring 30 coaxially received about the link 32and the plunger assembly 24 between an upper flange 31 and a retainingring 33. Lower plunger portion 28 is adapted to reciprocateindependently of upper plunger portion 26 and is permanently biasedtowards its innermost position by a compression spring 38 located in thespace 39 formed between the upper plunger portion 26 and the lowerplunger portion 28. Spring 38 is held in position by reduced diameterportions 27 and 29 extending from the lower end of the upper plungerportion 26 and the upper end of the lower plunger portion 28,respectively. As will be explained below, portions 27 and 29 are adaptedto engage during downward movement of upper plunger portion 26 to definea minimum effective length for the plunger assembly 24. A drain passage40, which communicates with flow passages (not shown) which communicatewith the engine drain channel D, is also provided between the upper andlower plunger portions to drain any leaked fuel which may enter space39. A variable sized lash 34 is formed between the reduced diameterportions 27 and 29 of the upper and lower plunger portions 26 and 28respectively. The lower end of the lower plunger portion 28 and thelower end of the first internal bore 15 define a variable volume fuelpressurization chamber 36 for receiving fuel from a fuel supply rail FS.

Fuel is provided to the injector, illustrated in FIG. 1, by a fuelsupply rail FS which is arranged to supply fuel to the pressurizationchamber 36 by way of a fuel supply passage 50 including check valve 52,which allows fuel to flow into the pressurization chamber 36 when thelevel of pressure in the fuel supply exceeds the level of pressure offuel within the pressurization chamber 36, but not in a reversedirection. The size of the pressurization chamber 36 can be varied foreach cycle of injection operation by varying the pressure of fuelsupplied to the pressurization chamber 36 to cause the lower plungerportion 28 to compress spring 38 until the force on the lower plungerportion 28 is balanced. As will be described further hereinafter,transfer passage 16 provides for the flow of fuel out of the variablevolume fuel pressurization chamber 36 to a valve assembly 60.

Controlling the flow of fuel out of the variable volume fuelpressurization chamber 36 is a valve assembly 60 including a valveelement 62 including a hollow sleeve and radially extending armature 64.The interior of the sleeve forms a flow passage 66 which is part of thetransfer passage 16. The figures of each embodiment show the flowpassage 66 as a center feed flow passage, but various other flowpassages may be used. However, the center feed flow passage eliminateshigh pressure interfaces which exist in other types of passages andvalve assemblies and results in a low volume high pressure flow whilealso minimizing the volume of fuel under compression.

Referring also now to FIGS. 2A and 2B, the valve assembly 60, and inparticular the valve element 62, moves between its outermost position,shown in FIG. 2A, and its innermost position, shown in FIG. 2B by,generally, a compression spring 68 and a solenoid assembly 70. Thesolenoid assembly 70 includes a stator 74 made of a paramagneticmaterial and a coil 76 for cooperating with the armature 64 of valveelement 62 to apply a force on the valve element to move it to theposition shown in FIG. 2A. The spring 68 is positioned within adownwardly opening recess 72 formed in the stator 74 and extends intocontact with armature 64 at the other end. When valve element 62 is inits innermost position, due to the deenergization of the solenoidassembly 70 and force of compression spring 68, the lower portion of thevalve element 62 is caused to engage a valve seat A formed in the innerbarrel 8.

As illustrated in FIG. 1, when valve element 62 moves away from seat A,due to the energization of the solenoid assembly 70, fluid communicationis established between the lower portion 58 (FIG. 1) of passage 16 whichcommunicates with the tip valve chamber 21, and the second internal bore14 which provides for venting and drainage of fuel into a drain passage78 which communicates with flow passages, not illustrated, whichcommunicate with the engine drain channel D. The valve element 62 isretained in its outermost position, thereby maintaining seat A in anopen position, by the energization of solenoid assembly 70.

As shown in FIG. 2B, a valve seat B is provided adjacent an upperportion of the valve element 62 in the inner barrel 8. When valveelement 62 moves to its innermost position (FIG. 2B) fuel is permittedto pass from the variable volume fuel pressurization chamber 36 throughthe flow passage 16, including transfer passage 66 and flow passages 58to the tip valve chamber 21. The valve element 62 is moved away fromseat B, by the spring 68 upon the deenergization of the solenoidassembly 70. The solenoid generates sufficient attractive force to raisethe valve element 62 against the force exerted by the spring 68 and tomaintain the upper end of valve element 62 in contact with valve seat Bto close thereby flow passage 16. Due to the position of valve seat B,the high fuel injection pressure developed in chamber 36 has very littletendency to move valve element 62 away from seat B since the high fuelpressure is applied essentially radially to valve element 62. The forceexerted by the spring 68 is of a sufficient amount to keep the valveelement 62 in its innermost position against any back pressure which mayexist while allowing the valve element 62 to move upwardly uponenergization of the solenoid assembly 70.

The operation of the embodiment illustrated in FIG. 1 can best beunderstood by also referring to FIG. 3, which illustrates the sequentialstages of a complete injector cycle. At the start of the cycle, prior tothe injection phase, the upper plunger portion 26 is in the outermostposition (i.e. fully retracted) and the position of the lower plungerportion 28 is dependent upon the amount of fuel metered into thevariable volume fuel pressurization chamber 36, as shown in step I ofFIG. 3. The valve element 62 is in its outermost position spaced fromseat A and engaging seat B as a result of the energization of thesolenoid assembly 70 in response to an energizing signal received froman electronic control module (not shown), creating a magnetic attractionbetween the stator 74 and armature 64 of the valve element 62, alsoillustrated in FIG. 2A. The tip valve element 20 is consequently in theinnermost position thereby closing the injector orifice 17, as alsoshown in FIG. 1.

Still referring to Step I of FIG. 3, fuel flows through the supplypassage 50 through, the check valve 52 and into the upper portion offlow passage 16. Seat B is contacted by the upper end of the valveelement 62 and, as a result, fuel is precluded from flowing into thetransfer passage 66. The volume of fuel which flows into the fuelpressurization chamber 36 is controlled by varying the fuel supplypressure provided through fuel supply rail FS. So long as the fuelsupply pressure is greater than the pressure of the fuel trapped in thefuel pressurization chamber 36, fuel Will continue to flow through thesupply passage 50, and the check valve 52, forcing lower plunger portion28 up towards upper plunger portion 26. As the lower plunger portion 28moves upwardly, the variable volume fuel pressurization chamber 36 isformed. As the volume of trapped fuel in the pressurization chamber 36increases, the downward force of coil spring 38 exerted against thelower plunger portion 28 also increases. As will be noted later, thelower plunger portion 2 will not always be at its innermost position atthe start of every injection cycle. The position of lower plungerportion 28 is dependent upon the volume of fuel left in thepressurization chamber 36 after the injection event has taken place.

The volume of fuel trapped in the pressurization chamber 36 is dependentupon the fuel supply rail pressure and the spring constant of spring 38which, in turn, sets the size of lash 34, between the reduced diameterportions 27 and 29 of the upper plunger portion 26 and the lower plungerportion 28. As noted above, the volume of fuel in the pressurizationchamber 36 will be increased only if the fuel supply rail pressure issufficient to overcome the force of spring 38, which urges the lowerplunger portion 28 outwardly towards the upper plunger portion 26. Whenthe fuel supply pressure is sufficient to overcome the force of coilspring 38, fuel will enter the variable volume fuel pressurizationchamber 36 forcing the lower plunger portion 28 outwardly towards theupper plunger portion 26. This outward movement of the lower plungerportion 28 functions to set the lash 34. When the fuel supply pressureis no longer sufficient to overcome the force of spring 38, fuel can nolonger flow into the pressurization chamber 36. At this point in thecycle, the fuel trapped in the pressurization chamber 36 will be at apressure substantially equivalent to the fuel supply pressure.

The lash-setting phase occurs while the upper plunger portion 26 is inthe outermost, fully retracted position. As shown in Step I of FIG. 3,during the lash-setting phase, the inner base 88 of the cam engages thecam follower 90. As the cam rotates and the cam follower 90 begins toscale the ramp or lift portion 92, the link 32 will begin to moveinwardly causing the upper plunger portion 26 to also move inwardly.Depending upon the size of the lash 34, lower plunger portion 28 willbegin to move inwardly as the reduced diameter portion 27 of the upperplunger portion 26 makes contact with the reduced diameter portion 29 ofthe lower plunger portion 28. This is shown in Step II of FIG. 3.

The fuel in the pressurization chamber 36 is trapped due to the blockageof passage 16 by valve element 62 of valve assembly 60 and the checkvalve 52 in flow passage 50. As the lower plunger portion 28 movesinwardly, the pressure of the trapped fuel in the fuel pressurizationchamber 36 is significantly increased. During the pressurization phase,the passage 16 remains closed preventing any fuel from entering the flowpassages to the tip valve chamber 21 and the injector orifice 17.

Referring now to Step III of FIG. 3, when the fuel pressurization phasehas been completed, the upper plunger portion 26 is in the innermost,fully advanced position and the cam is at peak lift. The fuel trapped inthe pressurization chamber 36 has been pressurized to the desired levelto inject the fuel at a predetermined peak injection pressure. Thepressurized fuel in the pressurization chamber 36 will begin to flow outof the chamber when valve element 62 is moved away from seat B.

As also illustrated in FIG. 2B, the solenoid assembly 70 is deenergizedin response to loss of the energizing signal from an electronic controlmodule (not shown), thereby terminating the magnetic attraction betweenthe stator 74 and armature 64 of the valve element 62. As a result, thespring 68 forces the valve element 62 in a downward direction, virtuallyinstantaneously opening transfer passage 16 and moving the valve element62 into contact with valve seat A. This is shown in Step III of FIG. 3.

Upon movement of valve element 62 away from seat B, the high pressurefuel Will flow through the transfer passage 66, into passages 58 leadingto the injector orifice 17. The fuel flowing through transfer passage 66into the passages 58 cannot enter drain passage 78 because valve element62 will engage seat A to block flow into drain passage 78. The fuel fromtransfer passage 66 will continue to flow through fuel passage 58 intothe tip valve chamber 21 surrounding the tip valve element 20. Thepressure of the fuel in the tip valve chamber 21 is sufficiently high todisplace tip valve element 20, thereby affecting the injection of fuelthrough the injector orifice 17.

Once a predetermined amount of fuel has been injected into the enginecylinder (not shown), the solenoid assembly 70 is reenergized, causingthe valve element 62 to be displaced in an upward direction, virtuallyinstantaneously engaging seat B and opening passage 78, ending theinjection of fuel, shown in Step IV of FIG. 3. The disengagement ofvalve element 62 from seat A will allow fuel to be vented through thedrain passage 78. The engagement of valve element 62 with seat B willprevent the flow of fuel out of the fuel pressurization chamber 36.Although no fuel enters the fuel pressurization chamber 36 during theinjection phase, the pressure of the fuel in the pressurization chamber36, while reduced from peak values, is still high.

Throughout the injection phase the cam is at peak lift and, therefore,the upper plunger portion 26 is in innermost, fully advanced position.After the injection phase, the cam will return to zero lift or its innerbase, causing the upper plunger portion 26 to retract, as shown in StepIV of FIG. 3. As described above, the upper plunger portion 26 isphysically connected to link 32, which is connected to a cam assembly(not shown) for actuating the upper plunger portion 26. Lower plungerportion 28, however, is adapted to reciprocate independently and is notbiased by spring 38 and would not follow except for the reasons outlinedbelow.

The present invention solves the no-follow problem by allowing the fuelin the pressurization chamber 36 to remain under high pressure after theinjection phase during the post-injection phase of operation. As aresult of the high pressure fuel trapped in the pressurization chamber36, when the upper plunger portion 26 initially retracts, the lowerplunger portion 28 will follow, until the inwardly directed force ofspring 38 is greater than the outwardly directed force of thepressurized fuel. In addition to solving the no-follow problem, theenergy stored in the fuel remaining in the fuel pressurization chamber36 is returned to the engine cam shaft due to the elasticcompressibility of the fuel.

As the upper plunger portion 26 continues to retract, the lash 34between the reduced diameter portions 27 and 29 of upper and lowerplunger portions 26 and 28 is reformed. When the upper plunger portion26 is fully retracted, the injection cycle is completed.

As will be appreciated by those skilled in the art, the valve assembly60 may be reversed, whereby the valve element 62 is maintained in theoutermost position, shown in FIG. 2A by the compression spring 68 andretracted to its innermost position, shown in FIG. 2B, by the solenoidassembly 70. In such a case the compression spring must be capable ofmaintaining the valve element 62 in the outermost position. It should benoted that the injection pressure is almost exclusively applied radiallyto the valve element except at its upper end which tends actually toassist the spring in holding the valve element against seat A.

As is apparent from the above discussion of the operation of the unitinjector of the present invention, the solenoid assembly 70, in responseto an electrical control signal, is able to control the timing ofinjection and the quantity of fuel injected on a cycle-by-cycle basis.If the timing and quantity of fuel injected is controlled in response tochanges in engine conditions, improved engine efficiency and pollutionabatement can be obtained.

As will also be appreciated by those skilled in the art, the solenoidcontrolled valve assembly 60 may also serve as a tip valve, such as isdescribed in U.S. patent application Ser. No. 540,288 to Wilber et al.,assigned to the applicant of the present invention.

The trapped volume of fuel in the variable volume fuel pressurizationchamber 36 is a crucial factor in the capability of the fuel injector ofthe present invention to maximize average injection pressure. Inparticular, by including the two-part plunger assembly 24, the disclosedinjector is able to control the injection pressure for each cycle ofinjection operation in dependence on the level of pressure of the fuelreceived from the fuel supply. As a result, average injection pressurefor each cycle can be maximized, thereby increasing engine operatingefficiency and pollution abatement. Further, because this novelarrangement allows for decoupling of the injection event from the inwardmovement of the upper plunger portion 26, injection pressure may becontrolled and varied independent of engine speed, thereby allowinginjection pressure to be set independently of the other engine operatingparameters and conditions. The ability to independently controlinjection pressure for each cycle of injection operation solely inresponse to fuel supply pressure substantially increases the injector'sability to maximize engine performance for the wide range of operatingenvironments and varying engine operating conditions.

The average injection pressure, which represents the average pressure ofthe fuel injected during the injection phase (i.e. during one cycle),can be substantially increased by increasing the trapped volume of fuelin the variable volume fuel pressurization chamber 36. As will bediscussed, increasing average injection pressures results in improvedatomization of the injected fuel, which has the positive effects of adrastic reduction in particulate and NOx emissions and greatly improvedengine performance.

Reference is now made to FIG. 4, which is a detailed graph of thetrapped volume as a function of the diameter of the lower plungerportion 28, given a constant peak injection pressure of 22,000 psi and aconstant delivery of fuel per cycle or stroke of 230 mm³. For a giventrapped volume of fuel in fuel pressurization chamber 36 and a lowerplunger portion 28 diameter, the graph indicates the resulting averagepressure (psi), link load (lb) and link travel (in).

The trapped volume of fuel in the fuel pressurization chamber 36 alsoprovides a means for introducing compliancy into the fuel injector ofthe present invention. Introducing compliancy into the mechanical driveassembly (i.e., the cam, link and plunger assembly) increases theability of the fuel injector of the present invention to achieve highaverage injection pressures, given a constant peak injection pressureand a constant amount of fuel delivered or injected per cycle or stroke.The pressure drop from peak injection pressure can be minimized with amore compliant system. Minimization of pressure drop will result in themaximization of average injection pressures.

The plunger assembly 24, link 32 and the cam assembly (not shown)comprise the mechanical portion of the fuel injector 2 and introducevirtually no compliancy into the system. Compliancy is introduced intothe fuel injector of the present invention from the trapped volume offuel in the fuel pressurization chamber 36, which serves as a hydrauliclink within the system. The trapped volume, upon pressurization, acts asa hydraulic spring with a hydraulic spring rate k, where k=(B·A²)/V,where B is the bulk modulus of diesel fuel, A is the area of the lowerplunger section 28 and V is the trapped volume of fuel in the fuelpressurization chamber 36. As is apparent from this equation, increasingthe trapped volume will decrease the hydraulic spring rate k, resultingin an increase in the system compliancy.

In the preferred embodiment of the present invention, link travel shouldbe in the range 0.20-0.35 in., link load should generally be less than3000 lb., and the average injection pressure should be maximized.Consequently, as can be determined from FIG. 4, a trapped volume in therange of 3000-5000 cubic millimeters is preferred.

In contrast to the design and operation of the fuel injectors shown inthe prior art, in the fuel injector of the present invention thepressurization of fuel by movement of a plunger mechanically connectedto the engine cam shaft by a link-cam assembly and the injection of thefuel through an injector orifice do not occur simultaneously. This noveland advantageous operation, in which the injection event is decoupledfrom movement of any mechanical connection to the cam shaft, allows forthe control and variation of injection pressure independent of enginespeed and substantially reduces hertz stresses placed on the mechanicalportions of the injector, resulting in a reduction in unwanted engineemissions by maximizing the average injection pressure.

As illustrated in FIGS. 5 and 6, the lift profile of the cam of thesubject invention is decoupled from the injection event and, therefore,as previously described, avoids the sharp radii of curvature required byknown injectors which attain high average injection pressures. As aresult of this decoupling, it is not necessary for the plunger, which isdriven by the cam assembly, to travel with high velocity to maximize theaverage injection pressure. The plunger can move inwardly, from theoutermost position to the desired inner position, with a relatively lowvelocity and, correspondingly, low rate of acceleration. The plunger cantravel the same distance, from the same beginning and ending points, ata much slower rate than that of the other injectors noted above.

Since plunger movement at a low velocity and low rate of acceleration isacceptable, no need exists for a sharply angled lift ramp or profile onthe cam. The ramp or lift portion of the cam, designated as 2 in FIGS. 5and 6, can be spread out over a greater portion of the cam surface. Inthe preferred embodiment of the present invention, the lift segment 2 ofthe cam is between 30°-120° of the circumference of the cam. Incontrast, the typical unit fuel injector, wherein injection pressure isdependent upon the velocity of an injector plunger traveling inwardlyduring the injection event, includes a cam wherein the lift segmentcomprises only 6° of the circumference of the cam. By significantlyincreasing the circumference of the cam comprising the lift portion, camhertz stresses resulting in wear on cam and cam follower surfaces aresubstantially decreased.

Referring to FIG. 5, the circumference of the cam is divided into foursuccessive unequal segments of 75° (segment 1), 120° (segment 2), 60°(segment 3) and 105° (segment 4). Segment 1, which lies on the innerbase circle portion 88 of the cam surface, is a retracted dwell segmentin which the cam's engagement with the cam follower 90 causes the upperplunger portion 26 to remain in its outermost, fully retracted positionwhile fuel is supplied to the variable volume fuel pressurizationchamber 36, setting the lash. During engagement of the cam follower bysegment 2, the plunger advancement segment, the upper plunger portion 26moves inwardly, toward the lower plunger portion 28, taking up the lashand causing pressurization of the fuel in the variable volume fuelpressurization chamber 36. Segment 3, which lies on the outer basecircle portion 94 of the cam surface, is the advanced dwell segment inwhich the cam causes the upper plunger portion 26 to remain in itsinnermost, fully advanced position, while the injection event takesplace. The final segment, segment 4, is a plunger retraction segmentwhich controls the retraction of the upper plunger portion 26. Thefollowing chart indicates the four phases of operation of the injectorcorresponding to the cam segment:

SEGMENT PHASE 1. Retracted Dwell Lash-Setting Phase 2. PlungerAdvancement Pressurization Phase 3. Advanced Dwell Injection Phase 4.Plunger Retraction Post-Injection Phase

The four segments have corresponding lift profile characteristics asillustrated in FIG. 6, which graphs the cam lift as a function of thecam degrees of rotation.

While the invention has been described with reference to the preferredembodiment, it will be appreciated by those skilled in the art that theinvention may be practiced otherwise than as specifically describedherein without departing from the spirit and the scope of the inventionlimited only by the appended claims.

Industrial Applicability

The solenoid controlled variable pressure fuel injector heretoforedescribed may be used in compression injection and spark injectionengines of any vehicle or industrial equipment where accurate controland variation of the timing of injection, metering of the properquantity of fuel and injection pressure is essential. The two-partplunger assembly in combination with the solenoid controlled twoposition valve element permits the fuel injector of the presentinvention, in operation, to decouple plunger advancement from injection.This advantageous operation results in a substantial reduction in hertzstresses while maximizing average injection pressures by varyinginjection pressure for each cycle of injection operation based on engineoperating conditions independent of engine speed.

What is claimed is:
 1. A unit fuel injector adapted to receive fuel froma fuel supply at relatively low pressure and adapted to inject fuel atrelatively high pressure into the combustion chamber of an internalcombustion engine, comprising: (a) an injector body containing a firstinternal bore and an injector orifice; (b) a plunger mounted forreciprocating movement within said first internal bore to define avariable volume fuel pressurization chamber into which fuel is receivedat low pressure from the fuel supply and from which fuel is dischargedperiodically at relatively high pressure for injection through saidinjector orifice into the combustion chamber; and (c) injection pressurecontrol means for causing fuel to be injected through the injectororifice at a pressure level which is dependent on variation in the levelof pressure of the fuel received from the fuel supply and which isindependent of changes in the velocity of the reciprocating movement ofsaid plunger.
 2. A unit fuel injector as defined in claim 1 for use inan internal combustion engine having a cam for operating said unitinjector, wherein said plunger includes an upper plunger portion whichis adapted to reciprocate between advanced and retracted position inresponse to the rotation of the cam and a lower plunger portion mountedin said first internal bore between said variable volume fuelpressurization chamber and said upper plunger portion.
 3. A unit fuelinjector as defined in claim 2, wherein said injection pressure controlmeans includes (a) supply means for directing low pressure fuel from thefuel supply into said variable volume fuel pressurization chamber whensaid upper plunger portion is in said retracted position; and (b)biasing means for biasing said plunger portions apart to thereby varythe volume of fuel which flows into said variable volume fuelpressurization chamber during each cycle of injection operation independence on the pressure of the fuel from the fuel supply.
 4. A unitfuel injector as defined in claim 3, wherein said upper plunger portionincludes a first reduced diameter portion extending toward said lowerplunger portion and said lower plunger portion includes a second reduceddiameter portion extending toward said upper plunger portion, saidreduced diameter portions being positioned to engage during the downwardmovement of said upper plunger portion to define the minimum effectivelength of said plunger.
 5. A unit fuel injector as defined in claim 4,wherein said biasing means includes a coil spring surrounding said upperand lower plunger reduced diameter portions.
 6. A unit fuel injector asdefined in claim 5, further including injection timing control means forcausing fuel injection during each cycle of injection operation to occuronly during the time when said upper plunger portion is in its fullyadvanced position so that injection pressure is independent of thevelocity at which said upper plunger portion moves between its retractedand advanced position.
 7. A unit fuel injector as defined in claim 6,wherein said injection timing control means is responsive to anelectrical control signal which is adapted to control both the timingand quantity of fuel injected on a cycle-to-cycle basis.
 8. A unit fuelinjector as defined in claim 7, wherein said injection timing controlmeans includes a valve assembly for controlling the flow of fuel fromsaid variable volume fuel pressurization chamber to said injectororifice.
 9. A unit fuel injector as defined in claim 8, wherein saidinjector body contains a transfer passage for fluid communicationbetween said variable volume fuel pressurization chamber and saidinjector orifice and wherein said valve assembly includes a valveelement reciprocating between: (a) a first position blocking the flow offuel from said variable volume fuel pressurization chamber to saidinjector orifice during movement of said upper plunger portion from itsretracted to its advanced position to pressurize the fuel trapped insaid fuel pressurization chamber to a relatively high pressure level;and (b) a second position permitting the relatively high pressure fuelto flow from said variable volume fuel pressurization chamber throughsaid injector orifice for discharge into the combustion chamber whilesaid upper plunger portion is held in its advanced position therebydecoupling movement of said upper plunger portion from the discharge offuel into the combustion chamber.
 10. A unit fuel injector as defined inclaim 9, wherein said valve assembly includes: a spring means forbiasing said valve element from said first position toward said secondposition; and an electronically actuated solenoid for moving said valveelement to said first position and for maintaining said valve element insaid first position upon receipt of an electrical control signal.
 11. Aunit fuel injector as defined in claim 10, further including check valvemeans for allowing fuel to flow into said variable volume fuelpressurization chamber when the pressure level within saidpressurization chamber is below the pressure level of the fuel supplyand for preventing reverse flow of fuel through said supply means whenthe pressure level in said pressurization chamber is above the pressurelevel of the fuel supply.
 12. A unit fuel injector as defined in claim11, wherein said valve element includes a hollow sleeve.
 13. A unit fuelinjector as defined in claim 12, wherein the hollow interior of saidsleeve forms a portion of said transfer passage.
 14. A unit injector asdefined in claim 13, wherein said valve assembly includes a first valveseat adjacent the upper end of said hollow sleeve, said first valve seatbeing engaged by the upper end of said hollow sleeve when said valveelement is in its first position.
 15. A unit injector as defined inclaim 14, wherein said valve assembly includes a second valve seatadjacent the lower end of said hollow sleeve, said second valve seatbeing engaged by the lower end of said hollow sleeve when said valveelement is in its second position.
 16. A unit injector as defined inclaim 15, wherein said hollow sleeve is co-axially mounted within saidinjector body with respect to said plunger.
 17. A unit injector asdefined in claim 16, wherein said solenoid is concentrically mountedabout said hollow sleeve
 18. A unit fuel injector as defined in claim15, wherein said injector body includes a drain passage for dischargingfuel from said unit injector and wherein said valve element in its firstposition forms an opening for permitting the flow of fuel from a tipvalve chamber, defined by a pressure actuated tip valve mounted forreciprocating movement in a third internal bore formed in said injectorbody for allowing the flow of fuel through said injector orifice to saidcombustion chamber only when the fuel pressure exceeds a predeterminedlevel, into said drain passage and in its second position blocks theflow of fuel from said tip valve chamber into said drain passage.
 19. Aunit fuel injector as defined in claim 2, wherein the reciprocatingmovement of said plunger is dependent upon the profile of said cam, saidcam profile including a plunger advancement segment for controlling thevelocity of upper plunger section advancement and an advanced dwellsegment for holding the upper plunger section in its advanced position20. A unit fuel injector as defined in claim 19, wherein said plungeradvancement segment is shaped to extend over a relatively long portionof the cam circumference to cause the upper plunger portion velocity tobe relatively low.
 21. A unit fuel injector as defined in claim 20,wherein said plunger advancement segment extends over at least 30° ofthe circumference of the cam.
 22. A unit fuel injector as defined inclaim 21, wherein said advanced dwell segment follows said plungeradvancement segment and is shaped to hold the upper plunger portion inits advanced position during the injection event thereby decouplingupper plunger portion advancement from the injection event.
 23. A unitfuel injector as defined in claim 2, further including a drive train forconverting rotational movement of said cam into reciprocating movementof the upper plunger portion depending on the profile of said cam andfor returning to the cam during each cycle the energy stored in the fuelremaining in the variable volume fuel pressurization chamber followingeach injection event due to the elastic compressibility of the fuel. 24.A unit fuel injector as defined in claim 3, wherein the maximum volumeof fuel trapped in said fuel pressurization chamber in any cycle is lessthan 5000 cubic millimeters.
 25. A unit fuel injector as defined inclaim 3, wherein the maximum volume of fuel trapped in said fuelpressurization chamber in any cycle is in the range of 3000 to 5000cubic millimeters.
 26. A unit fuel injector as defined in claim 3wherein the load applied by said cam to said upper plunger portion isequal to or less than 3000 pounds.
 27. A unit fuel injector as definedin claim 3 wherein the upper plunger portion travel is in the range of0.20 to 0.35 inches.
 28. A unit fuel injector adapted to receive fuelfrom a fuel supply at relatively low pressure and adapted to inject fuelat relatively high pressure into the combustion chamber of an internalcombustion engine, comprising: (a) an injector body having a firstinternal bore and an injector orifice; (b) a plunger mounted forreciprocating movement within said first internal bore to define avariable volume fuel pressurization chamber into which fuel is receivedat low pressure from the fuel supply and from which fuel is dischargedperiodically at relatively high pressure for injection through saidinjector orifice into the combustion chamber; and (c) injection pressurecontrol means for controlling the volume of low pressure fuel suppliedto the variable volume fuel pressurization chamber during each cycle tovary independent of engine speed the pressure at which fuel issubsequently injected into the combustion chamber within the same cycleof injection operation
 29. A unit fuel injector as defined in claim 28,for use in an internal combustion engine having a cam for operating saidunit injector, wherein said plunger includes an upper plunger portionwhich is adapted to reciprocate between advanced and retracted positionsin response to the rotation of the cam and a lower plunger portionmounted in said first internal bore between said variable volume fuelpressurization chamber and said upper plunger portion.
 30. A unit fuelinjector as defined in claim 29, wherein said injection pressure controlmeans includes: (a) supply means for directing low pressure fuel fromthe fuel supply into said variable volume fuel pressurization chamberwhen said upper plunger portion is in said retracted position; and (b)biasing means for biasing said plunger portions apart to thereby varythe volume of fuel which flows into said variable volume fuelpressurization chamber during each cycle of injection operation independence on the pressure of the fuel from the fuel supply.
 31. A unitfuel injector as defined in claim 30, wherein said upper plunger portionincludes a first reduced diameter portion extending toward said lowerplunger portion and said lower plunger portion includes a second reduceddiameter portion extending toward said upper plunger portion, saidreduced diameter portions being positioned to engage during the downwardmovement of said upper plunger portion to define the minimum effectivelength of said plunger.
 32. A unit fuel injector as defined in claim 31,further including injection timing control means for causing fuelinjection during each cycle of injection operation to occur only duringthe time when said upper plunger portion is in its fully advancedposition so that injection pressure is independent of the velocity atwhich said upper plunger portion moves between its retracted andadvanced position.
 33. A unit fuel injector as defined in claim 32,wherein said injection timing control means is responsive to anelectrical control signal which is adapted to control both the timingand quantity of fuel injected on a cycle-to-cycle basis.
 34. A unit fuelinjector as defined in claim 33, wherein said injection timing controlmeans includes a valve assembly for controlling the flow of fuel fromsaid variable volume fuel pressurization chamber to said injectororifice.
 35. A unit fuel injector as defined in claim 34, wherein saidinjector body contains a transfer passage for fluid communicationbetween said variable volume fuel pressurization chamber and saidinjector orifice wherein said valve assembly includes a valve elementreciprocating between: (a) a first position blocking the flow of fuelfrom said variable volume fuel pressurization chamber to said injectororifice during movement of said upper plunger portion from its retractedto its advanced position to pressurize the fuel trapped in said fuelpressurization chamber to a relatively high pressure level; and (b) asecond position permitting the relatively high pressure fuel to flowfrom said variable volume fuel pressurization chamber through saidinjector orifice for discharge into the combustion chamber while saidupper plunger portion is held in its advanced position therebydecoupling movement of said upper plunger portion from the discharge offuel into the combustion chamber.
 36. A unit fuel injector as defined inclaim 35, wherein said valve assembly includes: a spring means forbiasing said valve element from said first position toward said secondposition; and an electronically actuated solenoid for moving said valveelement to said first position and for maintaining said valve element insaid first position upon receipt of an electrical control signal
 37. Aunit fuel injector as defined in claim 36, further including check valvemeans for allowing fuel to flow into said variable volume fuelpressurization chamber when the pressure level within saidpressurization chamber is below the pressure level of the fuel supplyand for preventing reverse flow of fuel through said supply means whenthe pressure level in said pressurization chamber is above the pressurelevel of the fuel supply.
 38. A unit fuel injector as defined in claim37, further including a pressure actuated tip valve for allowing theflow of fuel through said injector orifice to said combustion chamberonly when the fuel pressure exceeds a predetermined level.
 39. A unitfuel injector as defined in claim 29, wherein the reciprocating movementof said plunger is dependent upon the profile of said cam, said camprofile including a plunger advancement segment for controlling thevelocity of upper plunger section advancement and an advanced dwellsegment for holding the upper plunger section in its advanced position.40. Unit fuel injector as defined in claim 39, wherein said plungeradvancement segment is shaped to extend over a relatively long portionof the cam circumference to cause the upper plunger portion velocity tobe relatively low.
 41. A unit fuel injector as defined in claim 40,wherein said plunger advancement segment extends over at least 30° ofthe circumference of the cam.
 42. A unit fuel injector as defined inclaim 41, wherein said advanced dwell segment follows said plungeradvancement segment and is shaped to hold the upper plunger portion inits advanced position during the injection event thereby decouplingupper plunger portion advancement from the injection event.
 43. A unitfuel injector as defined in claim 29, further including a drive trainfor converting rotational movement of said cam into reciprocatingmovement of the upper plunger portion depending on the profile of saidcam and for returning to the cam during each cycle the energy stored inthe fuel remaining in the variable volume fuel pressurization chamberfollowing each injection event due to the elastic compressibility of thefuel.
 44. A unit fuel injector as defined in claim 28, wherein saidinjection pressure control means controls the pressure at which fuel isinjected through the injector orifice dependent on variation in thelevel of pressure of the fuel received from the fuel supply andindependent of changes in the velocity of the reciprocating movement ofsaid plunger.
 45. A unit fuel injector as defined in claim 30, whereinthe maximum volume of fuel trapped in said fuel pressurization chamberin any cycle is less than 5000 cubic millimeters.
 46. A unit fuelinjector as defined in claim 30, wherein the maximum volume of fueltrapped in said fuel pressurization chamber in any cycle is in the rangeof 3000 to 5000 cubic millimeters.
 47. A unit fuel injector as definedin claim 30, wherein the load applied by said cam to said upper plungerportion is equal to or less than 3000 pounds.
 48. A unit fuel injectoras defined in claim 30, wherein the upper plunger portion travel is inthe range of 0.20 to 0.35 inches.
 49. A unit fuel injector adapted toreceive fuel from a fuel supply at relatively low pressure and adaptedto inject fuel at relatively high pressure into the combustion chamberof an internal combustion engine, comprising: (a) an injector bodyhaving a first internal bore and an injector orifice; (b) a plungermounted for reciprocating movement within said bore to define a variablevolume fuel pressurization chamber into which fuel is received at lowpressure from the fuel supply for elastic compression by said plungerand from which fuel is discharged periodically at relatively highpressure for injection through said injector orifice into the combustionchamber; and (c) means for utilizing the pressure of the fuel remainingin said variable volume fuel pressurization chamber as a result of theenergy stored in the fuel due to the elastic compressibility of the fuelfollowing each injection event to assist in retraction of said plunger.50. A unit fuel injector as defined in claim 48 49, for use in aninternal combustion engine having a cam and cam shaft for operating saidunit injector, wherein said plunger includes an upper plunger portionwhich is adapted to reciprocate between advanced and retracted positionsin response to the rotation of the cam and a lower plunger portionmounted in said first internal bore between said variable volume fuelpressurization chamber and said upper plunger portion; wherein saidmeans for utilizing acts on said lower plunger portion.
 51. A unit fuelinjector as defined in claim 50, wherein said means for returning duringeach cycle the energy stored in the fuel remaining in the variablevolume fuel pressurization chamber includes a drive train for linkingthe reciprocating movement of said upper plunger portion to therotational movement of said cam to thereby allow for the transfer of theenergy stored in the fuel pressurization chamber due to the elasticcompressibility of the fuel through the drive train to the cam.
 52. Aunit fuel injector as defined in claim 51, further including injectionpressure control means for causing fuel to be injected through theinjector orifice at a pressure level which is dependent on variation inthe level of pressure of the fuel received from the fuel supply andwhich is independent of changes in the velocity of the reciprocatingmovement of said plunger.
 53. A unit fuel injector as defined in claim52, wherein said injection pressure control means includes: (a) supplymeans for directing fuel from the fuel supply into said variable volumechamber when said upper plunger portion is in said retracted position;and (b) biasing means for biasing said plunger portions apart to therebyvary the volume of fuel in which flows into said variable volume fuelpressurization chamber during each cycle of injection operation independence on the pressure of the fuel from the fuel supply.
 54. A unitfuel injector as defined in claim 53, wherein said upper plunger portionincludes a first reduced diameter portion extending toward said lowerplunger portion and said lower plunger portion includes a second reduceddiameter portion extending toward said upper plunger portion, saidreduced diameter portions being positioned to engage during the downwardmovement of said upper plunger portion to define the minimum effectivelength of said plunger.
 55. A unit fuel injector as defined in claim 54,further including injection timing control means for causing fuelinjection during each cycle of injection operation to occur only duringthe time when said upper plunger portion is in its fully advancedposition so that injection pressure is independent of the velocity atwhich said upper plunger portion moves between its retracted andadvanced position.
 56. A unit fuel injector as defined in claim 55,wherein said injection timing control means is responsive to anelectrical control signal which is adapted to control both the timingand quantity of fuel injected on a cycle-to-cycle basis.
 57. A unit fuelinjector as defined in claim 56, wherein said injection timing controlmeans includes a valve assembly for controlling the flow of fuel fromsaid variable volume fuel pressurization chamber to said injectororifice.
 58. A unit fuel injector as defined in claim 57, wherein saidinjector body contains a transfer passage for fluid communicationbetween said variable volume fuel pressurization chamber and saidinjector orifice and wherein said valve assembly includes a valveelement reciprocating between: (a) a first position blocking the flow offuel from said variable volume fuel pressurization chamber to saidinjector orifice during movement of said upper plunger portion from itsretracted to its advanced position to pressurize the fuel trapped insaid fuel pressurization chamber to a relatively high pressure level;and (b) a second position permitting the relatively high pressure fuelto flow from said variable volume fuel pressurization chamber throughsaid injector orifice for discharge into the combustion chamber whilesaid upper plunger portion is held in its advanced position therebydecoupling movement of said upper plunger portion from the discharge offuel into the combustion chamber.
 59. A unit fuel injector as defined inclaim 58, wherein said valve assembly includes: a spring means forbiasing said valve element from said first position toward said secondposition; and an electronically actuated solenoid for moving said valveelement to said first position and for maintaining said valve element insaid first position upon receipt of an electrical control signal.
 60. Aunit fuel injector as defined in claim 59, further including check valvemeans for allowing fuel to flow into said variable volume fuelpressurization chamber when the pressure level within saidpressurization chamber is below the pressure level of the fuel supplyand for preventing reverse flow of fuel through said supply means whenthe pressure level in said pressurization chamber is above the pressurelevel of the fuel supply.
 61. A unit fuel injector as defined in claim60, further including a pressure actuated tip valve for allowing theflow of fuel through said injector orifice to said combustion chamberonly when the fuel pressure exceeds a predetermined level.
 62. A unitfuel injector as defined in claim 50, wherein the reciprocating movementof said plunger is dependent upon the profile of said cam, said camprofile including a plunger advancement segment for controlling thevelocity of upper plunger section advancement and an advanced dwellsegment for holding the upper plunger section in its advanced position.63. A unit fuel injector as defined in claim 62, wherein said plungeradvancement segment is shaped to . extend over a relatively long portionof the cam circumference to cause the upper plunger portion velocity tobe relatively low.
 64. A unit fuel injector as defined in claim 63,wherein said plunger advancement segment extends over at least 30° ofthe circumference of the cam.
 65. A unit fuel injector as defined inclaim 64, wherein said advanced dwell segment follows said plungeradvancement segment and is shaped to hold the upper plunger portion inits advanced position during the injection event thereby decouplingupper plunger portion advancement from the injection event.
 66. A unitfuel injector as defined in claim 53, wherein the maximum volume of fueltrapped in said fuel pressurization chamber in any cycle is less than5000 cubic millimeters.
 67. A unit fuel injector as defined in claim 53,wherein the maximum volume of fuel trapped in said fuel pressurizationchamber in any cycle is in the range of 3000 to 5000 cubic millimeters.68. A unit fuel injector as defined in claim 53, wherein the loadapplied by said cam to said upper plunger portion is equal to or lessthan 3000 pounds.
 69. A unit fuel injector as defined in claim 53,wherein the upper plunger portion travel is in the range of 0.20 to 0.35inches.
 70. A unit fuel injector adapted to receive fuel from a fuelsupply at relatively low pressure and adapted to inject fuel atrelatively high pressure into the combustion chamber of an internalcombustion engine, comprising: (a) an injector body having a firstinternal bore and an injector orifice; (b) a plunger mounted forreciprocating movement within said first internal bore to define avariable volume fuel pressurization chamber into which fuel is receivedat low pressure from the fuel supply and from which fuel is dischargeperiodically at relatively high pressure for injection through saidinjector orifice into the combustion chamber; and (c) injection pressurecontrol means for responding to a hydraulic control signal defined bythe pressure level of the fuel received from the fuel supply for varyinginjection pressure during each cycle of injection operationsubstantially independent of engine speed over substantially the entirerange of engine operating speeds.
 71. A unit fuel injector adapted toreceive fuel from a fuel supply at relatively low pressure and adaptedto inject fuel at relatively high pressure into the combustion chamberof an internal combustion engine, comprising: (a) an injector bodyhaving a first internal bore and an injector orifice; (b) a plungermounted for reciprocating movement with said first internal bore todefine a variable volume fuel pressurization chamber into which fuel isreceived at low pressure form the fuel supply and from which fuel isdischarged periodically at relatively high pressure for injectionthrough said injector orifice into the combustion chamber; and (c)injection pressure control means for responding to a hydraulic controlsignal for varying injection pressure substantially independent ofengine speed; for use in an internal combustion engine having a cam foroperating said unit injector, wherein said plunger includes an upperplunger portion which is adapted to reciprocate between advanced andretracted positions in response to the rotation of the cam and a lowerplunger portion mounted in said first internal bore between saidvariable volume fuel pressurization chamber and said upper plungerportion.
 72. A unit fuel injector as defined in claim 71, wherein saidinjection pressure control means includes: (a) supply means fordirecting low pressure fuel from the fuel supply into said variablevolume fuel pressurization chamber at a predetermined pressure leveldefining said hydraulic control signal when said upper plunger portionis in said retracted position; and (b) biasing means for biasing saidplunger portions apart to thereby vary the volume of fuel which flowsinto said variable volume fuel pressurization chamber during each cycleof injection operation in dependence on said hydraulic control signal.73. A unit fuel injector as defined in claim 72, wherein said upperplunger portion includes a first reduced diameter portion extendingtoward said lower plunger portion and said lower plunger portionincludes a second reduced diameter portion extending toward said upperplunger portion, said reduced diameter portions being positioned toengage during the downward movement of said upper plunger portion todefine the minimum effective length of said plunger.
 74. A unit fuelinjector as defined in claim 73, further including injection timingcontrol means for responding to an electrical control signal for varyingthe timing of fuel injection during each cycle of injection operationcausing fuel injection during each cycle of injection operation to occuronly during the time when said upper plunger portion is in its fullyadvanced position so that injection pressure is independent of thevelocity at which said upper plunger portion moves between its retractedand advanced position.
 75. A unit fuel injector as defined in claim 74,wherein said injection timing control means is responsive to anelectrical control signal which is adapted to control both the timingand quantity of fuel injected on a cycle-to-cycle basis.
 76. A unit fuelinjector as defined in claim 75, wherein said injection timing controlmeans includes a valve assembly for controlling the flow of fuel fromsaid variable volume fuel pressurization chamber to said injectororifice.
 77. A unit fuel injector as defined in claim 76, wherein saidinjector body contains a transfer passage for fluid communicationbetween said variable volume fuel pressurization chamber and saidinjector orifice and wherein said valve assembly includes a valveelement reciprocating between: (a) a first position blocking the flow offuel from said variable volume fuel pressurization chamber to saidinjector orifice during movement of said upper plunger portion from itsretracted to its advanced position to pressurize the fuel trapped insaid fuel pressurization chamber to a relatively high pressure level;and (b) a second position permitting the relatively high pressure fuelto flow from said variable volume fuel pressurization chamber throughsaid injector orifice for discharge into the combustion chamber Whilesaid upper plunger portion is held in its advanced position therebydecoupling movement of said upper plunger portion from the discharge offuel into the combustion chamber.
 78. A unit fuel injector as defined inclaim 77, wherein said valve assembly includes: a spring means forbiasing said valve element from said first position toward said secondposition; and an electronically actuated solenoid for moving said valveelement to said first position and for maintaining said valve element insaid first position upon receipt of an electrical control signal.
 79. Aunit fuel injector as defined in claim 78, further including check valvemeans for allowing fuel to flow into said variable volume fuelpressurization chamber when the pressure level within saidpressurization chamber is below the pressure level of the fuel supplyand for preventing reverse flow of fuel through said supply means Whenthe pressure level in said pressurization chamber is above the pressurelevel of the fuel supply.
 80. A unit fuel injector as defined in claim79, further including a pressure actuated tip valve for allowing theflow of fuel through said injector orifice to said combustion chamberonly when the fuel pressure exceeds a predetermined level.
 81. A unitfuel injector as defined in claim 71, wherein the reciprocating movementof said plunger is dependent upon the profile of said cam, said camprofile including a plunger advancement segment for controlling thevelocity of upper plunger section advancement and an advanced dwellsegment for holding the upper plunger section in its advanced position.82. A unit fuel injector as defined in claim 81, wherein said plungeradvancement segment is shaped to extend over a relatively long portionof the cam circumference to cause the upper plunger portion velocity tobe relatively low.
 83. A unit fuel injector as defined in claim 82,wherein said plunger advancement segment extends over at least 30° ofthe circumference of the cam.
 84. A unit fuel injector as defined inclaim 83, wherein said advanced dwell segment follows said plungeradvancement segment and is shaped to hold the upper plunger portion inits advanced position during the injection event thereby decouplingupper plunger portion advancement from the injection event.
 85. A unitfuel injector as defined in claim 71, further including a drive trainfor converting rotational movement of said cam into reciprocatingmovement of the upper plunger portion depending on the profile of saidcam and for returning to the cam during each cycle the energy stored inthe fuel remaining in the variable volume fuel pressurization chamberfollowing each injection event due to the elastic compressibility of thefuel.
 86. A unit fuel injector as defined in claim 72, wherein themaximum volume of fuel trapped in said fuel pressurization chamber inany cycle is less than 5000 cubic millimeters.
 87. A unit fuel injectoras defined in claim 72, wherein the maximum volume of fuel trapped insaid fuel pressurization chamber in any cycle is in the range of 3000 to5000 cubic millimeters.
 88. A unit fuel injector as defined in claim 72,wherein the load applied by said cam to said upper plunger portion isequal to or less than 3000 pounds.
 89. A unit fuel injector as definedin claim 72, wherein the upper plunger portion travel is in the range of0.20 to 0.35 inches.
 90. A unit fuel injector adapted to receive fuelfrom a fuel supply at relatively low pressure and adapted to inject fuelat relatively high pressure into the combustion chamber of an internalcombustion engine, comprising: (a) an injector body having a firstinternal bore and an injector orifice; (b) a plunger mounted forreciprocating movement within said first internal bore to define avariable volume fuel pressurization chamber into which fuel is receivedat low pressure from the fuel supply and from which fuel is dischargedperiodically at relatively high pressure for injection through saidinjector orifice into the combustion chamber; (c) injection pressurecontrol means for responding to a hydraulic control signal defined bythe pressure level of the fuel received from the fuel supply for varyinginjection pressure substantially independent of engine speed oversubstantially the entire range of engine generator speeds; and (d)injection timing control means for responding to a second control signalfor varying the timing of fuel injection during each cycle of injectoroperation.
 91. A unit fuel injector as defined in claim 90, for use inan internal combustion engine having a cam for operating said unitinjector, wherein said plunger includes an upper plunger portion whichis adapted to reciprocate between advanced and retracted positions inresponse to the rotation of the cam and a lower plunger portion mountedin said first internal bore between said variable volume fuelpressurization chamber and said upper plunger portion.
 92. A unit fuelinjector as defined in claim 91, wherein said injection pressure controlmeans includes: (a) supply means for directing low pressure fuel fromthe fuel supply into said variable volume fuel pressurization chamber ata predetermined pressure level defining said second control signal whensaid upper plunger portion is in said retracted position; and (b)biasing means for biasing said plunger portions apart to thereby varythe volume of fuel which flows into said variable volume fuelpressurization chamber during each cycle of injection operation independence on said second control signal.
 93. A unit fuel injector asdefined in claim 92, wherein said upper plunger portion includes a firstreduced diameter portion extending toward said lower plunger portion andsaid lower plunger portion includes a second reduced diameter portionextending toward said upper plunger portion, said reduced diameterportions being positioned to engage during the downward movement of saidupper plunger portion to define the minimum effective length of saidplunger.
 94. A unit fuel injector as defined in claim 93, wherein saidinjection timing control means includes a valve assembly for controllingthe flow of fuel from said variable volume fuel pressurization chamberto said injector orifice in response to said second control signal. 95.A unit fuel injector as defined in claim 94, wherein said injector bodycontains a transfer passage for fluid communication between saidvariable volume fuel pressurization chamber and said injector orificeand wherein said valve assembly includes a valve element reciprocatingbetween: (a) a first position blocking the flow of fuel from saidvariable volume fuel pressurization chamber to said injector orificeduring movement of said upper plunger portion from its retracted to itsadvanced position to pressurize the fuel trapped in said fuelpressurization chamber to a relatively high pressure level; and (b) asecond position permitting the relatively high pressure fuel to flowfrom said variable volume fuel pressurization chamber through saidinjector orifice for discharge into the combustion chamber while saidupper plunger portion is held in its advanced position in response tosaid second control signal thereby decoupling movement of said upperplunger portion from the discharge of fuel into the combustion chamber.96. A unit fuel injector as defined in claim 95, wherein said valveassembly includes: a spring means for biasing said valve element fromsaid first position toward said second position; and an electronicallyactuated solenoid for moving said valve element to said first positionand for maintaining said valve element in said first position uponreceipt of said second control signal.
 97. A unit fuel injector asdefined in claim 96, further including check valve means for allowingfuel to flow into said variable volume fuel pressurization chamber whenthe pressure level within said pressurization chamber is below thepressure level of the fuel supply and for preventing reverse flow offuel through said supply means when the pressure level in saidpressurization chamber is above the pressure level of the fuel supply.98. A unit fuel injector as defined in claim 97, further including apressure actuated tip valve for allowing the flow of fuel through saidinjector orifice to said combustion chamber only when the fuel pressureexceeds a predetermined level.
 99. A unit fuel injector as defined inclaim 90, wherein said first control signal is a hydraulic controlsignal and said second control signal is an electrical control signal.100. A unit fuel injector as defined in claim 91, wherein thereciprocating movement of said plunger is dependent upon the profile ofsaid cam, said cam profile including a plunger advancement segment forcontrolling the velocity of upper plunger section advancement and anadvanced dwell segment for holding the upper plunger section in itsadvanced position.
 101. A unit fuel injector as defined in claim 99,wherein said plunger advancement segment is shaped to extend over arelatively long portion of the cam circumference to cause the upperplunger portion velocity to be relatively low.
 102. A unit fuel injectoras defined in claim 101, wherein said plunger advancement segmentextends over at least 30° of the circumference of the cam.
 103. A unitfuel injector as defined in claim 102, wherein said advanced dwellsegment follows said plunger advancement segment and is shaped to holdthe upper plunger portion in its advanced position during the injectionevent thereby decoupling upper plunger portion advancement from theinjection event.
 104. A unit fuel injector as defined in claim 91,further including a drive train for converting rotational movement ofsaid cam into reciprocating movement of the upper plunger portiondepending on the profile of said cam and for returning to the cam duringeach cycle the energy stored in the fuel remaining in the variablevolume fuel pressurization chamber following each injection event due tothe elastic compressibility of the fuel.
 105. A unit fuel injector asdefined in claim 92, wherein the maximum volume of fuel trapped in saidfuel pressurization chamber in any cycle is less than 5000 cubicmillimeters.
 106. A unit fuel injector as defined in claim 92, whereinthe maximum volume of fuel trapped in said fuel pressurization chamberin any cycle is in the range of 3000 to 5000 cubic millimeters.
 107. Aunit fuel injector as defined in claim 92, wherein the load applied bysaid cam to said upper plunger portion is equal to or less than 3000pounds.
 108. A unit fuel injector as defined in claim 92, wherein theupper plunger portion travel is in the range of 0.20 to 0.35 inches.109. A unit injector as defined in claim 49, further including aninjection timing control valve for causing fuel injection during eachcycle of injection operation, said injection timing control valveresponsive to an electrical control signal which is adapted to controlboth the timing and quantity of fuel injected on a cycle-by-cycle basis.110. A unit injector as defined in claim 109, wherein the unit fuelinjector further includes a drain passage, said injection timing controlvalve is movable between a first position blocking high pressure fuelflow to said drain passage and a second position permitting highpressure fuel flow to said drain passage.
 111. A unit injector asdefined in claim 49, wherein said means for utilizing the pressure ofthe fuel to assist in the retraction of the plunger, acts on saidplunger for returning during each cycle the energy stored in the fuel tothe engine.
 112. A unit injector as defined in claim 111, wherein theengine includes a cam and cam shaft for operating the unit injector,said means for utilizing the pressure of the fuel to assist in theretraction of the plunger and for returning during each cycle the energystored in the fuel to the engine including a drive train for linking thereciprocating movement of the plunger to the rotational movement of thecam to thereby allow for the transfer of the energy stored in the fuelpressurization chamber due to the elastic compressibility of the fuelthrough the drive train to the cam.
 113. A unit injector as defined inclaim 49, further including a pressure actuated tip valve for allowingthe flow of fuel through said injector orifice to said combustionchamber only when the fuel pressure exceeds a predetermined level. 114.A unit injector as defined in claim 49, wherein a maximum volume of fueltrapped in said fuel pressurization chamber in any cycle is less than5000 cubic millimeters.
 115. A unit injector as defined in claim 49,wherein a load applied by a cam to said plunger is equal to or less than3000 pounds.